Mitsubishi Fuso FE.FG.FK.FM Series Repair Service Manual 2008-2010
Complete service repair manual with Electrical Wiring Diagrams for Mitsubishi Fuso FE.FG.FK.FM Series 2008-2010, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
2008-2010 Mitsubishi Fuso FE.FG.FK.FM Series workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
Mitsubishi Fuso FE.FG.FK.FM Series 2008-2010 Service Manual (PWME0806&TWME0709&TWSE0713&TWSE0805).pdf
Mitsubishi Fuso FK.FM Series 2008 Owner's Manual (MH997284).pdf
Mitsubishi Fuso FK.FM Series Body Builder's Drawings & Supporting Data (LTE07001-A - 2007.09).pdf
PRODUCT DETAILS:
Total Pages: 5,790 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
FE.FG.FK.FM Series 2008-2010 Fuso Service Manual (PWME0806&TWME0709&TWSE0713&TWSE0805)...1
2008 Service Manual...1
2008 FE/FG Service Manual...2
Group 00 - General...3
Table of Contents...4
Equipment Type Codes List...5
Power Train Table...6
How To Read This Manual...7
Chassis Number, Engine Number, Power Train Label...11
Vehicle Identification Number...12
Precautions for Maintenance Operation...13
Jacking Up the Vehicle...25
Diagnosis Codes...27
1. Diagnosis Codes...27
2. Reading and Erasing the Diagnosis Code...28
Table of Standard Tightening Torques...33
Group 01 - Maintenance Schedule...36
Table of Contents...37
How to Read the Maintenance Schedule Tables...38
Maintenance Schedule Tables...40
Maintenance Operations...44
Lubrication Tables...50
Lubrication...52
Group 11 - Engine...56
Table of Contents...57
Specifications...58
Structure and Operation...59
1. Exploded View...59
2. Cylinder Head, Cylinder Head Gasket, Camshaft and Camshaft Frame...60
3. Valve Mechanism...61
4. Connecting Rod...62
5. Piston...62
6. Timing Gears...63
7. Flywheel...63
8. Balance Shafts...64
9. Crankcase and Main Bearings...65
10. Oil Seals...67
Troubleshooting...68
On-Vehicle Inspection and Adjustment...70
1. Measuring Compression Pressure...70
2. Inspection and Adjustment of Valve Clearances...72
3. Removal and Installation of Injector Crew Cab (Fixed Type)...74
Engine Removal and Installation...76
Tilt Cab...76
Fixed Cab...84
Rocker Cover...86
Rockers and Camshafts...88
Cylinder Head and Valve Mechanism...102
Pistons, Connecting Rod and Cylinder Liners...118
Flywheel...132
Front Case...136
Timing Gears and Balance Shafts...140
Crankshaft and Crankcase...148
Balance Shaft Bushings...156
Group 12 - Lubrication...161
Table of Contents...162
Specifications...163
Structure and Operation...164
1. Lubrication System...164
2. Oil Pump...165
3. Oil Cooler...166
4. Oil Filter...167
5. Lubrication of Engine Components...168
Troubleshooting...171
On-Vehicle Inspection and Adjustment...173
1. Oil Filter Replacement...173
2. Engine Oil Replacement...177
3. Engine Oil Level Inspection...179
4. Oil Pressure Measurement...180
Oil Pan, Oil Strainer and Oil Jets...181
Oil Pump...183
Oil Filter...187
Oil Cooler...191
Group 13A - Fuel and Engine Control...193
Table of Contents...194
Specifications...195
Structure and Operation...196
1. Fuel System (Flow of Fuel)...196
2. Engine Control...197
3. Fuel Filter...198
Troubleshooting...199
On-Vehicle Inspection and Adjustment...201
1. Inspecting and Adjusting No-Load Minimum and Maximum Speeds...201
2. Air-Bleeding of Fuel System...202
3. Fuel Filter Replacement...203
Fuel Tank...205
Outside Frame Type...205
Inside Frame Type...207
Fuel Filter...209
Engine Control...213
Common Rail...217
Supply Pump...221
Injector...225
Group 13EA - Common Rail System...228
Table of Contents...229
Specifications...230
Structure and Operation...231
1. Overview...231
2. Electronic Control System...240
3. Electronic Control Unit Connection Diagram...248
Troubleshooting...250
1. Diagnosis Procedure...250
2. Diagnostic Precautions...250
3. Inspection Based on Fault Codes...251
4. Multi-Use Tester Service Data...1192
5. Mode 06 Data...1196
6. Actuator Tests Performed Using Multi-Use Tester...1198
Registration and Alteration of Data In Engine Electronic Control Unit...1202
1. Operation at Electronic Control Unit Replacement...1202
2. Resetting the Diesel Particulate Filter Related Information (Resetting Electronic Control Unit)...1202
Inspection of Electrical Equipment...1204
Installed Locations of Parts...1214
Electric Circuit Diagram...1220
Group 13EB - Auto Cruise and Vehicle Speed Limitation System...1225
Table of Contents...1226
Structure and Operation...1227
1. General Description...1227
2. Electronic Control System...1227
3. Electronic Control Unit Connection Diagram...1231
Troubleshooting...1233
1. Diagnosis Procedure...1233
2. Diagnostic Precautions...1234
3. Inspection Based on Diagnosis Codes...1235
4. Multi-Use Tester Service Data...1239
5. Actuator Tests Performed Using Multi-Use Tester...1240
6. Works Required When Replacing the Multifunction Vehicle Control Unit (MVCU)...1240
7. Inspection Performed at Electronic Control Unit Connectors...1241
Inspection of Electrical Equipment...1242
Installed Locations of Parts...1243
Electric Circuit Diagram...1247
Group 14 - Cooling...1249
Table of Contents...1250
Specifications...1251
Structure and Operation...1253
1. Cooling System (Flow of Coolant)...1253
2. Thermostat...1254
3. Water Pump...1254
Troubleshooting...1255
On-Vehicle Inspection and Adjustment...1257
1. Inspection and Adjustment of Belt Tension...1257
2. Inspection of Cracks or Damage of the Belt...1262
3. Coolant Replacement and Cleaning of Cooling System...1263
4. Air Bleeding of Cooling System...1265
5. Air/Gas Leakage Test...1265
Disconnection and Connection of Hoses and Pipes...1267
Radiator, Fan Shroud...1271
Cooling fan, Belt and Water Pump...1279
Tension Pulley...1282
Thermostat...1283
Pressure Cap and Water Outlet Case...1285
Group 15 - Intake and Exhaust...1287
Table of Contents...1288
Specifications...1289
Structure and Operation...1289
1. Air Cleaner...1289
2. Turbocharger...1290
3. Turbocharger Control System...1291
4. Diesel Particulate Filter Regeneration Control System...1295
Troubleshooting...1305
On-Vehicle Inspection and Adjustment...1307
1. Measurement of Turbocharger Boost Pressure...1307
2. Cleaning and Inspection of Air Cleaner Element...1308
3. Diesel Particulate Filter Unit Inspection for Clogging and Cleaning the Diesel Particulate Filter Unit...1309
4. Resetting the DPF-Related Information (Resetting Electronic Control Unit)...1313
Air Duct and Air Cleaner...1317
Except Crew Cab...1317
Crew Cab...1321
Turbocharger...1325
Intercooler...1331
Intake Manifold...1335
Exhaust Manifold...1337
Exhaust Pipe...1339
Diesel Particulate Filter...1341
Group 17 - Emission Control...1347
Table of Contents...1348
Structure and Operation...1349
1. Exhaust Gas Recirculation System...1349
2. Crankcase Emission Control System...1354
Exhaust Gas Recirculation Valve, Pipe and Cooler...1355
Crankcase Emission Control System...1359
Group 21 - Clutch...1362
Table of Contents...1363
Specifications...1364
Structure and Operation...1365
1. Clutch Control...1365
2. Clutch Master Cylinder...1366
3. Clutch Proper and Clutch Direct Power Cylinder...1368
Troubleshooting...1370
On-Vehicle Inspection and Adjustment...1372
1. Replacement of Brake Fluid (Clutch System)...1372
2. Air Bleeding of Brake Fluid (Clutch System)...1374
3. Inspection of Clutch Disc Wear Limit...1376
Clutch Pedal...1378
Clutch Master Cylinder...1382
Clutch Proper...1384
Clutch Control...1388
Group 22 - Manual Transmission...1393
Table of Contents...1394
Specifications...1395
Structure and Operation...1397
1. Transmission...1397
2. Synchromesh Mechanism...1399
3. Interlock Mechanism...1402
4. Speedometer Gear Bushing...1402
Troubleshooting...1403
On-Vehicle Inspection and Adjustment...1405
1. Inspection of Transmission Oil Leak...1405
2. Inspection of Looseness in Transmission Mounting Bolts...1405
3. Inspection of Play In Companion Flange and Looseness in Lock Nut...1406
4. Inspection and Replacement of Transmission Oil...1406
Removal and Installation of Transmission...1409
Gear Shifter Upper...1413
Rear Cover S5 and Parking Brake...1419
Extension Housing S6 and Parking Brake...1423
Reverse Idler Gear...1429
6th Gear S6...1433
Transmission Body...1439
Drive Pinion...1455
Mainshaft...1457
Countershaft...1467
Transmission Control...1469
Bearing Puller and Installer...1473
Group 23 - Automatic Transmission...1474
Table of Contents...1475
Specifications...1476
Structure and Operation...1477
1. Overview...1477
2. Electronic Control System...1483
3. Electronic Control Unit Connection Diagram...1488
Troubleshooting...1490
1. Diagnosis Procedure...1490
2. Diagnostic Precautions...1490
3. Inspections Based on Diagnosis Codes...1491
4. Multi-Use Tester Service Data...1789
5. Possible Causes of Symptoms...1792
On-Vehicle Inspection and Adjustment...1796
1. Inspection of Automatic Transmission Oil Leakage...1796
2. Check for Looseness in Automatic Transmission Mounting Bolts...1796
3. Inspection of Play in Companion Flange and Looseness in Lock Nut...1797
4. Inspection of Automatic Transmission Fluid...1797
5. Replacement of Automatic Transmission Fluid...1798
6. Stall Test...1800
7. Time Lag Test...1801
8. Line Pressure Test...1802
9. Road Test...1804
10. Dealer Adjust...1805
Removal and Installation of Automatic Transmission...1808
Parking Brake...1814
Automatic Transmission Control...1816
Oil Cooler...1826
Except Crew Cab...1826
Crew Cab...1828
Replacement of Part of Automatic Transmission Main Body...1830
Inspection of Electrical Equipment...1834
Installed Locations of Parts...1838
Electric Circuit Diagram...1842
Group 24 - Transfer...1846
Table of Contents...1847
Specifications...1848
Structure and Operation...1849
1. Transfer...1849
2. Speedometer Gear Bushing...1850
Troubleshooting...1851
On-Vehicle Inspection and Adjustment...1852
1. Inspection of Looseness in Transmission and Transfer Mounting Bolts...1852
2. Inspection of Play and Looseness in Companion Flange...1852
3. Inspection and Replacement of Transfer Oil...1853
Removal and Installation of Transmission (With Transfer)...1854
Removal and Installation of Transfer...1858
Front Drive...1860
Rear Drive...1866
Transfer...1872
Transfer Control (High-Low Switching)...1880
Group 25 - Propeller Shaft...1884
Table of Contents...1885
Specifications...1886
Structure and Operation...1886
1. Configuration of Propeller Shaft Connection...1886
2. Propeller Shaft Without Center Bearing...1887
3. Propeller Shaft With Center Bearing...1888
Troubleshooting...1889
Removal and Installation of Propeller Shaft...1890
Between T/M (or T/F) and Rear Axle...1890
Between Front Axle and T/F...1892
Propeller Shaft...1894
P2...1894
P3...1900
Group 26A - Front Axle FE...1911
Table of Contents...1912
Specifications...1913
Structure and Operation...1914
1. Wheel Hub and Rotor...1914
2. Knuckle and Kingpin, Front Axle...1915
Troubleshooting...1916
On-Vehicle Inspection and Adjustment...1917
1. Inspection and Adjustment of Wheel Alignment...1917
2. Inspection and Adjustment of Steering Angle...1921
3. Inspection of Side Slip...1922
4. Inspection of Tie Rod End Ball Joint...1922
Wheel Hub and Rotor...1923
Knuckle and Kingpin, Front Axle...1933
Tie Rod...1941
Group 26B - Front Axle FG...1943
Table of Contents...1944
Specifications...1945
Structure and Operation...1945
1. Wheel Hub and Brake Drum...1945
2. Free Wheel Hub...1946
3. Drive Shaft and Steering Knuckle, Axle Housing...1947
4. Reduction and Differential...1948
Troubleshooting...1949
On-Vehicle Inspection and Adjustment...1953
1. Inspection and Adjustment of Wheel Alignment...1953
2. Inspection and Adjustment of Steering Angle...1957
3. Inspection of Side Slip...1957
4. Inspection of Tie Rod End Ball Joint...1958
5. Inspection and Replacement of Axle Oil...1958
Wheel Hub and Brake Drum...1961
Drive Shaft and Steering Knuckle...1973
Tie Rod...1979
Axle Housing...1981
Reduction and Differential...1983
Group 27 - Rear Axle...1998
Table of Contents...1999
Specifications...2000
Structure and Operation...2001
1. Wheel Hub and Rotor...2001
2. Wheel Hub and Brake Drum...2002
3. Reduction and Differential...2003
4. Limited Slip Differential...2004
Troubleshooting...2006
On-Vehicle Inspection and Adjustment...2008
1. Inspection and Replacement of Axle Oil...2008
Wheel Hub and Rotor...2010
Wheel Hub and Brake Drum...2020
Axle Housing...2032
Reduction and Differential...2036
Group 31 - Wheel and Tire...2063
Table of Contents...2064
Specifications...2065
Troubleshooting...2066
Wheel and Tire...2067
Group 33 - Front Suspension...2072
Table of Contents...2073
Structure and Operation...2074
1. Front Suspension Elements...2074
Troubleshooting...2075
Stabilizer...2076
Shock Absorber...2078
FE...2078
FG...2080
Leaf Spring...2082
FE...2082
FG...2086
Group 34 - Rear Suspension...2090
Table of Contents...2091
Structure and Operation...2092
1. Rear Suspension Elements...2092
Troubleshooting...2093
Shock Absorber...2094
Leaf Spring...2096
Stabilizer...2112
Group 35A - Brake...2115
Table of Contents...2116
Specifications...2117
Structure and Operation...2119
1. Brake System...2119
2. Vacuum Pump...2122
3. Vacuum Booster and Brake Master Cylinder Except FE85...2123
4. Hydraulic Booster and Brake Master Cylinder FE85...2129
5. Flow Priority Valve FE85...2135
6. Front Disc Brake FE...2136
7. Front Drum Brake FG...2137
8. Rear Disc Brake FE...2140
9. Rear Drum Brake FG...2141
10. Exhaust Brake System FE...2142
Troubleshooting...2145
On-Vehicle Inspection and Adjustment...2149
1. Replacement of Brake Fluid...2149
2. Air Bleeding of Brake System...2151
3. Inspection and Adjustment of Brake Pedal Free Play...2155
4. Inspection and Adjustment of Brake Pedal Pressed Height from Floor...2155
5. Inspection of Brake Pedal Full Stroke and Adjustment of Installed Height of Brake Pedal...2156
6. Inspection and Replacement of Disc Brake Pad FE...2157
7. Measurement of Disc Brake Drag Torque FE...2160
8. Inspection of Drum Brake Lining Thickness FG...2160
9. Initial Setting of Clearance Between Brake Drum and Shoe FG...2161
10. Inspection of Check Valve in Vacuum Line Hose...2162
11. Inspection of Vacuum Pump...2162
12. Inspection of Vacuum Booster Except FE85...2163
13. Inspection of Hydraulic Booster FE85...2168
Vacuum Pump...2170
Brake Master Cylinder...2171
With Vacuum Booster...2171
With Hydraulic Booster...2175
Brake Pedal & Vacuum Booster, Hydraulic Booster...2177
Front Disc Brake...2179
235 mm {9.25 in.} Disc...2179
252 mm {9.92 in.} Disc...2183
Front Drum Brake...2187
Rear Disc Brake...2193
235 mm {9.25 in.} Disc...2193
252 mm {9.92 in.} Disc...2195
Rear Drum Brake...2197
Exhaust Brake System...2203
Group 35E - Anti-Lock Brake System (ABS)...2205
Table of Contents...2206
Specifications...2207
Structure and Operation...2209
1. Overview...2209
2. Electronic Control System...2219
3. Electronic Control Unit Schematic Diagram...2223
Troubleshooting...2225
1. Diagnosis Procedure...2225
2. Diagnostic Precautions...2225
3. Diagnosis Based on Diagnosis Codes...2226
4. Multi-Use Tester Service Data...2232
5. Actuator Test Using Multi-Use Tester...2234
6. Inspection at Hydraulic Unit (Electronic Control Unit) Connector...2235
On-Vehicle Inspection and Adjustment...2237
1. Functional Check...2237
2. Inspection of Hydraulic Unit (Electronic Control Unit) Operation...2238
3. Inspection After Replacing or Removing/Installing Hydraulic Unit (Electronic Control Unit)...2239
4. Oscilloscopic Inspection Through Wheel Speed Sensor Signal Waveform...2240
Hydraulic Unit Connector Coupling and Uncoupling...2241
Inspection of Electrical Components...2243
Components Location...2245
Electrical Wiring Diagram...2247
Group 36 - Parking Brake...2249
Table of Contents...2250
Specifications...2251
Structure and Operation...2252
1. Components and Parts...2252
2. Parking Brake Lever...2252
3. Parking Brake...2253
Troubleshooting...2254
On-Vehicle Inspection and Adjustment...2255
1. Adjustment of Parking Brake Shoe Clearance...2255
2. Inspection and Adjustment of Parking Brake Lever...2256
Parking Brake Control...2259
Parking Brake...2263
FE (Manual Transmission)...2263
FE (Automatic Transmission)...2265
FG...2267
Group 37 - Steering...2269
Table of Contents...2270
Specifications...2271
Structure and Operation...2273
1. Steering System...2273
2. Oil Flow...2273
3. Power Steering Gear (Backlash Compensation Mechanism)...2274
4. Power Steering Oil Pump KYB Product...2275
5. Power Steering Oil Pump Unisia JKC Steering Systems Product...2277
Troubleshooting...2279
On-Vehicle Inspection and Adjustment...2281
1. Change of Power Steering Fluid...2281
2. Bleeding of Power Steering System...2282
3. Performance Verification Test of Power Steering System...2283
4. Steering Wheel Play...2284
5. Steering Column Looseness...2284
6. Inspection of Drag Link Ball Joint...2284
Steering Column...2285
Power Steering Gear Assembly and Drag Link...2295
Power Steering Oil Pump...2313
KYB Product...2313
Unisia JKC Steering Systems Product...2317
Power Steering Oil Tank...2321
Group 41 - Bumper and Frame...2323
Table of Contents...2324
Specifications...2325
Structure and Operation...2326
Front Bumper...2327
Frame...2329
Group 42 - Cab...2334
Table of Contents...2335
Specifications...2336
Structure and Operation...2337
1. Front Cab Mounting...2337
2. Rear Cab Mounting Except Crew Cab...2338
3. Center and Rear Cab Mountings Crew Cab...2338
4. Cab Tilt Link Except Crew Cab...2339
Troubleshooting...2340
On-Vehicle Inspection and Adjustment...2342
1. Adjustment of Cab Tilt System Except Crew Cab...2342
Removal and Installation of Cab...2344
Except Crew Cab...2344
Crew Cab...2348
Front Cab Mounting...2352
Except Crew Cab...2352
Crew Cab...2354
Rear Cab Mounting Except Crew Cab...2356
Center and Rear Cab Mountings Crew Cab...2357
Cab Tilt Link Except Crew Cab...2358
Cab Stay Except Crew Cab...2360
Group 43 - Door...2361
Table of Contents...2362
Specifications...2363
Structure and Operations...2364
1. Front Door Lock System...2364
2. Rear Door Lock System Crew Cab...2364
3. Front Door Glass Opening and Closing Mechanism...2365
4. Rear Door Glass Opening and Closing Mechanism Crew Cab...2367
Troubleshooting...2369
On-Vehicle Inspection and Adjustment...2371
1. Adjustment of Front Door Alignment...2371
2. Adjustment of Rear Door Alignment Crew Cab...2374
Front Door...2377
Rear Door Crew Cab...2385
Group 51 - Exterior...2392
Table of Contents...2393
Structure and Operation...2394
1. Wiper and Washer System...2394
Troubleshooting...2395
Mirror...2396
Wiper and Washer...2398
Front Cover...2400
Front Grille, Front Corner Panel and Headlamp...2402
Fender...2406
Step...2408
Garnish Crew Cab...2410
Wheel House...2411
Window Glass...2412
Group 52 - Interior...2415
Table of Contents...2416
Seat...2417
Driver...2417
Passenger...2419
Rear...2421
Seat Belt...2423
Instrument Panel...2429
Trim and Scuff Plate...2443
Except Crew Cab...2443
Crew Cab...2447
Head Lining...2449
Except Crew Cab...2449
Crew Cab...2451
Group 54 - Electrical...2453
Table of Contents...2454
How to Read This Group...2457
54-00A - General...2461
Precautions for Maintenance Operation...2462
54-00B - Specifications...2472
Specifications...2473
54-00C - Structure and Operation...2476
1. Starter...2477
2. Alternator...2478
3. Headlamps...2481
4. Meter Cluster...2482
5. Daytime Running Light System...2491
6. Wiper Control...2493
7. Starter Continuous Energizing Preventing Function and Preheating Function...2495
54-00D - Troubleshooting...2498
Troubleshooting...2499
54-01 - Power, Charge and Ground Circuit...2507
High-Current Fuse Box...2508
Fuse Box...2510
110 - Power Circuit...2512
115 - Reserve Power Circuit...2525
125 - Battery Charging Circuit...2526
130 - Ground...2528
54-02 - Starting, Stopping and Preheating Circuit...2546
210 - Engine Starting Circuit...2547
215 - Engine Stopping Circuit...228
220 - Engine Preheating Circuit...2549
54-03 - Lighting Circuit...2551
310 - Headlamp Circuit...2552
313 - Daytime Running Light Circuit...2554
320 - Tail, Clearance and License Plate Lamps Circuit...2556
325 - Stop Lamp Circuit...2558
330 - Turn Signal and Hazard Lamp Circuit...2560
340 - Backup Lamp Circuit...2562
345 - Cab Lamp Circuit...2564
348 - Illumination Lamp Circuit...2566
349 - Identification Lamp and Side Marker Lamp Circuit...2567
352 - Van Body Dome Light Circuit...2568
54-04 - Meter Circuit...2569
401 - Meter Cluster Internal Circuit...2570
410 - Tachometer Circuit...2572
412 - Speedometer Circuit...2573
420 - Fuel Gauge Circuit...2574
425 - Water Temperature Gauge Circuit...2575
54-05 - Indicator and Warning Lamp Circuit...2576
510 - Parking Brake Indicator Circuit...2577
515 - Brake Warning Circuit...2579
535 - Engine Oil Level Warning Circuit...2581
536 - Engine Oil Pressure Warning Circuit...2582
537 - Overheating Warning Circuit...2583
540 - Brake Pad Warning Circuit...2584
550 - Cab Tilt Warning Circuit...2585
566 - Fuel Filter Warning Circuit...2586
54-06 - Cab Side Electrical Circuit...2587
610 - Cigarette Lighter Circuit...2588
612 - Audio Circuit...2589
614 - Wiper and Washer Circuit...2590
616 - Horn Circuit...2591
620 - Air-Conditioner Circuit...2592
622 - Power Window and Central Door Lock Circuit...2594
629 - Mirror Heater Circuit...2595
54-07 - Chassis Side Electrical Circuit...2596
710 - Exhaust Brake Circuit...2597
54-08 - Engine and Transmission Electrical Circuit...2599
810 - Four-Wheel Drive Circuit FG...2600
850 - Transmission Power Take-Off Circuit...2601
54-09 - Other Circuit...2602
905 - Joint Connector (J/C)...2603
907 - Diagnosis Switch and Memory Clear Switch...2607
Electronically Controlled Fuel System Electric Circuit Diagram...228
Auto Cruise System Electric Circuit Diagram...1225
Automatic Transmission System Electric Circuit Diagram...1474
Anit-Lock Brake System Electric Circuit Diagram...2205
54-10 - Electrical Equipment Installation Positions...2608
A - Switch...2609
B - Relay and Electronic Control Unit...2613
C - Fuse, Meter, Sensor, Buzzer, Motor and Actuator...2615
D - Air-Conditioner...2616
E - Door...2617
F - Roof...2618
J - Joints of Main Harness Connectors...2619
R - Engine...2621
S - Transmission...2623
T - Switch and Sensor...2626
U - Fuse, Relay and Connectors...2627
V - Magnetic Valve and Motor...2630
W - Buzzer and Connectors...2630
54-11 - Inspection of Electrical Equipment...2631
#001 to #179 - Switch...2632
#180 to #249 - Relay...2638
#250 to #349 - Sensor...2639
#350 to #409 - Control Unit...2640
#410 to #509 - Motor...2641
#510 to #539 - Actuator...2643
#560 to #609 - Magnetic Valve...2643
#610 to #649 - Buzzer, Horn...2644
#650 to #699 - Lamp...2646
#750 to #859 - Other...2647
#860 - Battery...2649
#890 - Meter...2652
54-12 - Starter and Alternator...2653
#930 - Starter...2654
#940 - Alternator...2668
54-13 - On-Vehicle Inspection and Adjustment...2676
#950 - Inspection of Alternator...2677
#951 - Inspection of Regulator...2678
#955 - Inspection of Preheating System...2679
#960 - Headlamp Aiming...2681
54-14 - Connector Configuration Chart...2683
Connector Configuration Chart...2684
Group 55 - Heater, Air-Conditioner and Ventilation...2766
Table of Contents...2767
Specifications...2768
Structure and Operation...2770
1. Heater...2770
2. Air Conditioner...2771
3. Air Duct...2772
4. Heater Control...2773
Troubleshooting...2776
On-Vehicle Inspection and Adjustment...2778
1. Recovery of Refrigerant...2778
2. Recharging the System With Refrigerant...2779
3. Checking Refrigerant Charge Level...2781
4. Adding Refrigerant...2782
Connecting Air Conditioner Piping...2783
Compressor...2784
Condenser, Receiver...2786
Heater Control...2788
Air Duct...2792
Heater and Cooling Unit, Blower...2794
2008 FK/FM Service Manual...2797
Group 00 - General...2798
Table of Contents...2799
Equipment Type Codes List...2800
Power Trains Table...2802
How To Read This Manual...2804
Chassis Number, Engine Number, Power Train Label...2808
Vehicle Identification Number...2809
Precautions for Maintenance Operation...2810
Jacking Up the Vehicle...2822
Diagnosis Codes...2824
1. Diagnosis Codes...2824
2. Reading and Erasing the Diagnosis Code...2825
Table of Standard Tightening Torques...2832
Group 01 - Maintenance Schedule...2835
Table of Contents...2836
How To Read the Maintenance Schedule Tables...2837
Maintenance Schedule Tables...2839
Maintenance Operations...2847
Lubrication Tables...2853
Lubrication...2855
Group 11 - Engine...2859
Table of Contents...2860
Specifications...2861
Structure and Operation...2862
1. Engine Proper...2862
2. Rocker and Bracket Assembly, Camshaft, Rocker Case and Cylinder Head Gasket...2863
3. Valve Mechanism...2864
4. Connecting Rod...2864
5. Piston...2865
6. Timing Gears...2865
7. Flywheel...2867
Troubleshooting...2868
On-Vehicle Inspection and Adjustment...2869
1. Measuring Compression Pressure...2869
2. Inspection and Adjustment of Valve Clearances...2873
Engine Removal and Installation...2877
Rocker Cover, Rocker and Bracket, Camshaft...2879
Cylinder Head and Valve Mechanism...2889
Piston and Connecting Rod, Cylinder Liner...2909
Flywheel...2923
Manual Transmission...2923
Automatic Transmission...2931
Timing Gears...2935
Crankshaft and Crankcase...2941
Group 12 - Lubrication...2951
Table of Contents...2952
Specifications...2953
Structure and Operation...2954
1. Lubrication System...2954
2. Oil Pump...2955
3. Oil Cooler...2956
4. Oil Filter...2957
5. Lubrication of Engine Components...2958
Troubleshooting...2962
On-Vehicle Inspection and Adjustment...2963
1. Oil Filter Replacement...2963
2. Engine Oil Replacement...2965
3. Engine Oil Level Inspection...2966
4. Oil Pressure Measurement...2967
Oil Pan, Oil Jets and Oil Level Sensor...2968
Oil Pump, Oil Strainer...2971
Oil Filter...2974
Oil Cooler...2975
Regulator Valve...2977
Group 13A - Fuel and Engine Control...2978
Table of Contents...2979
Specifications...2980
Structure and Operation...2981
1. Fuel System (Flow of Fuel)...2981
2. Engine Control...2982
3. Fuel Filter...2983
Troubleshooting...2984
On-Vehicle Inspection and Adjustment...2986
1. Inspecting No-Load and Maximum Speeds...2986
2. Air-Bleeding of Fuel System...2987
3. Fuel Filter Replacement...2988
Fuel Tank...2990
Fuel Filter...2991
Engine Control...2994
Common Rail...3000
Supply Pump...3002
Injector...3004
Group 13EA - Common Rail System...3007
Table of Contents...3008
Specifications...3009
Structure and Operation...3011
1. Overview...3011
2. Electronic Control System...3019
3. Electronic Control Unit Connection Diagram...3029
Troubleshooting...3031
1. Diagnosis Procedure...3031
2. Diagnostic Precautions...3031
3. Inspections Based on Fault Codes...3032
4. Multi-Use Tester Service Data...3751
5. Actuator Tests Performed Using Multi-Use Tester...3756
6. Registration and Alteration of Data in Engine Electronic Control Unit...3759
7. Initialization of Supply Pump Unit Difference Learning Value in Engine Electronic Control Unit...3760
Inspection of Electrical Equipment...3761
Installed Locations of Parts...3771
Electric Circuit Diagram...3779
Group 13EB - Auto Cruise and Vehicle Speed Limitation System...3788
Table of Contents...3789
Structure and Operation...3790
1. General Description...3790
2. Electronic Control System...3790
3. Electronic Control Unit Connection Diagram...3794
Troubleshooting...3796
1. Diagnostic Procedure...3796
2. Diagnostic Precautions...3796
3. Inspection Based on Diagnosis Codes...3797
4. Multi-Use Tester Service Data...3801
5. Actuator Tests Performed Using Mulit-Use Tester...3802
6. Works Required When Replacing the Multifunction Vehicle Control Unit (MVCU)...3802
7. Inspections Performed at Electronic Control Unit Connectors...3803
Inspection of Electrical Equipment...3804
Installed Locations of Parts...3806
Electric Circuit Diagram...3812
Group 14 - Cooling...3816
Table of Contents...3817
Specifications...3818
Structure and Operation...3819
1. Cooling System (Flow of Coolant)...3819
2. Thermostat...3820
3. Water Pump...3820
Troubleshooting...3821
On-Vehicle Inspection and Adjustment...3822
1. Inspection and Adjustment of Belt Tension...3822
2. Inspection of Cracks or Damage of the Belt...3824
3. Coolant Replacement and Cleaning of Cooling System...3825
4. Air Bleeding of Cooling System...3827
5. Gas Leakage Test...3827
Disconnection and Connection of Hoses and Pipes...3828
Radiator and Fan Shroud...3832
Cooling Fan, Belt and Water Pump...3842
Thermostat...3844
Group 15 - Intake and Exhaust...3846
Table of Contents...3847
Specifications...3848
Structure and Operation...3849
1. Air Cleaner...3849
2. Turbocharger...3850
3. Reducing Valve...3852
4. Diesel Particulate Filter Regeneration Control System...3853
Troubleshooting...3862
On-Vehicle Inspection and Adjustment...3864
1. Measurement of Turbocharger Boost Pressure...3864
2. Cleaning and Inspection of Air Cleaner Element...3866
3. Diesel Particulate Filter Unit Inspection for Clogging and Cleaning the Diesel Particulate Filter Unit...3867
4. Resetting the DPF-Related Information (Resetting Electronic Control Unit)...3871
Air Cleaner and Air Duct...3874
Turbocharger...3878
Intercooler...3884
Intake Manifold...3886
Exhaust Manifold...3888
Exhaust Pipe...3890
Diesel Particulate Filter...3896
Group 17 - Emission Control...3902
Table of Contents...3903
Structure and Operation...3904
1. Exhaust Gas Recirculation System...3904
2. Blowby Gas Return System...3909
On-Vehicle Inspection and Adjustment...3910
1. Replacement of PCV Valve Element...3910
EGR Valve, EGR Pipe and EGR Cooler...3912
Blowby Gas Return System...3914
Group 21 - Clutch...3915
Table Of Contents...3916
Specifications...3917
Structure and Operation...3918
1. Clutch Control...3918
2. Clutch Master Cylinder...3919
3. Clutch Proper...3921
Troubleshooting...3923
On-Vehicle Inspection and Adjustment...3925
1. Replacement of Brake Fluid (Clutch System)...3925
2. Air Bleeding of Brake Fluid (Clutch System)...3927
3. Clutch Pedal Play...3929
4. Clearance Between Clutch Pedal and Floor...3930
5. Clutch Action...3930
Clutch Pedal...3931
Clutch Master Cylinder...3935
Clutch Power Cylinder...3937
Clutch Proper...3939
Clutch Control...3951
Group 22A - Manual Transmission M060S6, M070S6...3953
Table of Contents...3954
Specifications...3955
Structure and Operation...3956
1. Transmission...3956
2. Synchromesh Mechanism...3957
3. Power Shift...3960
4. Interlock Mechanism...3962
Troubleshooting...3963
On-Vehicle Inspection and Adjustment...3965
1. Inspection of Transmission Oil Leakage...3965
2. Inspection of Looseness in Transmission Mounting Bolts...3965
3. Inspection of Play and Looseness in Companion Flange...3965
4. Inspection and Replacement of Transmission Oil...3966
Removal and Installation of Transmission...3967
Gear Shifter Upper and Interlock Plate...3971
Power Shift...3977
Extension Housing and Parking Brake...3985
Reverse Idler Gear M060...3991
6th Gear M060...3993
Reverse Gear and Reverse Idler Gear M070...3999
Transmission Body...4003
Drive Pinion...4021
Mainshaft...4023
M060...4023
M070...4035
Countershaft...4047
Transmission Control...4051
Puller and Installer Kit...4055
Group 23A - Automatic Transmission M065A5 (Allison 1000RDS, 2200RDS)...4056
Table of Contents...4057
Specifications...4058
Structure and Operation...4060
1. Outline...4060
2. Electronic Control System...4065
3. Electronic Control Unit Connection Diagram...4068
Troubleshooting...4070
1. Failure by Equipment...4070
On-Vehicle Inspection and Adjustment...4074
1. Inspection of Automatic Transmission Oil Leakage...4074
2. Check for Looseness in Automatic Transmission Mounting Bolts and Nuts...4074
3. Inspection of Play and Looseness in Companion Flange...4075
4. Inspection of Automatic Transmission Cooling System...4075
5. Inspection of Automatic Transmission Fluid...4076
6. Replacement of Automatic Transmission Fluid...4078
7. Replacement of Oil Filter...4079
8. Stall Test...4080
9. Line Pressure Test...4082
10. Road Test...4083
Removal and Installation of Automatic Transmission...4084
Parking Brake FK61...4088
Automatic Transmission Control...4090
Oil Cooler...4096
Parts Replacement of Automatic Transmission Proper...4098
Inspection of Electrical Equipment...4100
Installed Locations of Parts...4104
Electrical Circuit Diagram...4110
Group 23B - Automatic Transmission M100A6 (Allison 3000RDS)...4114
Table of Contents...4115
Specifications...4116
Structure and Operation...4118
1. Automatic Transmission...4118
2. Automatic Transmission Control System...4119
3. Oil Cooler System...4120
4. Electronic Control Unit Connection Diagram...4122
Troubleshooting...4124
1. Reading/Clearing of Diagnosis Codes...4124
2. List of Diagnosis Codes...4125
On-Vehicle Inspection and Adjustment...4128
1. Inspection of Automatic Transmission Oil Leakage...4128
2. Check for Looseness in Automatic Transmission Mounting Bolts...4128
3. Inspection of Play and Looseness in Companion Flange...4129
4. Inspection of Automatic Transmission Cooling System...4129
5. Inspection of Automatic Transmission Fluid...4130
6. Replacement of Automatic Transmission Fluid...4132
7. Level Check of Automatic Transmission Fluid...4134
8. Replacement of Oil Filter...4135
9. Stall Test...4136
10. Line Pressure Test...4137
11. Road Test...4140
Oil Cooler...4142
Inspection of Electrical Equipment...4146
Installed Locations of Parts...4148
Electrical Circuit Diagram...4154
Group 25 - Propeller Shaft...4158
Table of Contents...4159
Specifications...4160
Structure and Operation...4160
1. Configuration of Propeller Shaft Connection...4160
2. Propeller Shaft Without Center Bearing...4161
3. Propeller Shaft With Center Bearing...4161
Troubleshooting...4162
Removal and Installation of Propeller Shaft...4164
Propeller Shaft...4166
P8...4166
P10...4180
Group 26A - Front Axle FK61...4194
Table of Contents...4195
Specifications...4196
Structure and Operation...4197
1. Wheel Hub and Brake Drum...4197
2. Front Axle, Knuckle and Kingpin...4197
Troubleshooting...4198
On-Vehicle Inspection and Adjustment...4200
1. Inspection and Adjustment of Wheel Alignment...4200
2. Inspection and Adjustment of Steering Angle...4204
3. Inspection of Side Slip...4204
4. Inspection of Tie Rod End Ball Joint...4205
5. Inspection of Wheel Bearing for Play...4205
6. Inspection of Knuckle Joint for Play...4205
Wheel Hub and Brake Drum...4206
Front Axle, Knuckle and Kingpin...4220
Tie Rod...4228
Group 26B - Front Axle FK62, FK65, FM...4231
Table of Contents...4232
Specifications...4233
Structure and Operation...4234
1. Wheel Hub and Brake Drum...4234
2. Front Axle, Knuckle and Kingpin...4235
Troubleshooting...4236
On-Vehicle Inspection and Adjustment...4237
1. Inspection and Adjustment of Wheel Alignment...4237
2. Inspection and Adjustment of Steering Angle...4241
3. Inspection of Side Slip...4241
4. Inspection of Tie Rod End Ball Joint...4242
5. Inspection of Wheel Bearing for Play...4242
6. Inspection of Knuckle Joint for Play...4242
Wheel Hub and Brake Drum...4243
Front Axle, Knuckle and Kingpin...4259
FK...4259
FM...4267
Tie Rod...4275
Group 27 - Rear Axle...4278
Table of Contents...4279
Specifications...4280
Structure and Operation...4281
1. Wheel Hub and Brake Drum...4281
2. Reduction and Differential...4283
Troubleshooting...4284
On-Vehicle Inspection and Adjustment...4286
1. Adjustment of Wheel Speed Sensor Gap...4286
2. Inspection and Replacement of Differential Oil...4288
3. Inspection of Wheel Bearing for Play...4289
Wheel Hub and Brake Drum...4290
Axle Housing...4310
Reduction and Differential...4314
Group 31 - Wheel and Tire...4335
Table of Contents...4336
Specifications...4337
Troubleshooting...4338
On-Vehicle Inspection and Adjustment...4339
1. Inspection of Wheel Nut, Hub Bolt and Disc Wheel...4339
Wheel and Tire...4341
Group 33 - Front Suspension...4349
Table of Contents...4350
Structure and Operation...4351
1. Front Suspension...4351
Troubleshooting...4352
Shock Absorber...4353
Leaf Spring...4355
Group 34A - Rear Suspension LEAF...4362
Table of Contents...4363
Structure and Operation...4364
1. Rear Suspension...4364
Troubleshooting...4365
Shock Absorber...4366
Leaf Spring...4368
Group 34B - Rear Suspension AIR...4377
Table of Contents...4378
Specifications...4379
Structure and Operation...4379
1. Air Suspension...4379
2. Air Suspension System...4380
3. Leveling Valve...4381
Troubleshooting...4382
On-Vehicle Inspection and Adjustment...4383
1. Adjustment of Air Spring Height...4383
Leveling Valve...4384
Air Spring...4387
Shock Absorber...4391
Leaf Spring...4393
Lateral Rod...4395
Supply Valve...4398
Group 35A - Brake AIR-OVER HYDRAULIC BRAKE...4398
Table of Contents...4399
Specifications...4400
Structure and Operation...4402
1. Brake System...4402
2. Air Compressor...4404
3. Air Dryer...4405
4. Dual Brake Valve...4408
5. Brake Booster...4414
6. Fluid Tank...4416
7. Front Drum Brake...4417
8. Rear Drum Brake...4420
9. Supply Valve...4421
10. Quick Release Valve...4421
Troubleshooting...4422
On-Vehicle Inspection and Adjustment...4425
1. Exhaust Noise from Brake Valve...4425
2. Air Pressure Build-Up...4425
3. Replacement of Brake Fluid...4426
4. Air Bleeding of Brake System...4428
5. Inspection and Adjustment of Brake Pedal Free Play...4431
6. Inspection of Drum Brake Lining Thickness...4431
7. Initial Adjustment of Clearance Between Brake Drum and Shoe...4432
8. Maintenance and Inspection of Air Dryer...4434
9. Inspection and Adjustment of Air Dryer's Air Pressure Governor...4435
Handling of Nylon Tube for Air Line...4438
Compression Type...4438
Tube Identification Colors...4440
Handling of Connector...4441
Air Compressor...4442
Air Dryer...4446
Brake Pedal...4450
Dual Brake Valve...4452
Brake Booster...4458
Fluid Tank...4464
Front Wheel Brake...4466
Rear Wheel Brake...4474
Check Valve...4482
Safety Valve...4483
Supply Valve...4484
Quick Release Valve...4486
Group 35B - Brake FULL AIR BRAKE...4488
Table of Contents...4489
Specifications...4490
Structure and Operation...4492
1. Brake System...4492
2. Air Compressor...4398
3. Air Dryer...4398
4. Dual Brake Valve...4398
5. Front Drum Brake...4496
6. Rear Drum Brake...4500
7. Relay Valve...4502
8. Quick Release Valve...4398
9. Supply Valve...4398
Troubleshooting...4504
On-Vehicle Inspection and Adjustment...4508
1. Exhaust Noise from Brake Valve...4398
2. Air Pressure Build-Up...4398
3. Inspection and Adjustment of Brake Pedal Free Play...4398
4. Inspection of Brake Lining Thickness...4508
5. Initial Adjustment of Clearance Between Brake Drum and Shoe...4509
6. Maintenance and Inspection of Air Dryer...4398
7. Inspection and Adjustment of Air Dryer's Air Pressure Governor...4398
Handling of Nylon Tube for Air Line...4398
Compression Type...4398
Tube Identification Colors...4398
Handling of Connector...4398
Air Compressor...4398
Air Dryer...4398
Brake Pedal...4398
Dual Brake Valve...4398
Front Wheel Brake...4510
Rear Wheel Brake...4520
Expander...4532
Check Valve...4398
Safety Valve...4398
Relay Valve...4540
Supply Valve...4398
Quick Release Valve...4398
Group 35E - Anti-Lock Brake System (ABS)...4542
Table of Contents...4543
Specifications...4544
Structure and Operation...4546
1. General Description...4546
2. Electronic Control System...4552
3. Electronic Control Unit Schematic Diagram...4554
Troubleshooting...4556
1. Diagnosis Procedure...4556
2. Diagnostic Precautions...4556
3. Inspections Based on Diagnosis Codes...4557
4. Multi-Use Tester Service Data...4574
5. Electronic Control Unit Information Display...4574
6. Actuator Test Using Multi-Use Tester...4575
7. Inspection at Electronic Control Unit Connector...4578
On-Vehicle Inspection and Adjustment...4580
1. Functional Check...4580
2. Oscilloscopic Inspection through Wheel Speed Sensor Signal Waveform...4584
Inspection of Electrical Components...4586
Components Location...4588
Electrical Wiring Diagram...4592
Group 36A - Parking Brake CENTER PARKING BRAKE...4595
Table of Contents...4596
Specifications...4597
Structure and Operation...4598
1. Parking Brake System...4598
2. Parking Brake Lever...4599
3. Parking Brake...4599
Troubleshooting...4600
On-Vehicle Inspection and Adjustment...4601
1. Adjustment of Parking Brake Shoe Clearance...4601
2. Inspection and Adjustment of Parking Brake Lever...4602
Parking Brake Control...4603
Parking Brake...4607
Group 36B - Parking Brake WHEEL PARKING BRAKE...4609
Table of Contents...4610
Structure and Operation...4611
1. Parking Brake System...4611
2. Parking Brake Control Valve...4612
3. Spring Brake Valve...4613
4. Relay Valve (With Double Check Valve)...4616
Troubleshooting...4617
On-Vehicle Inspection and Adjustment...4619
1. Manual Release of Parking Brake...4619
Parking Brake Control Valve...4621
Spring Brake Valve...4623
Double Check Valve...4626
Relay Valve (With Double Check Valve)...4627
Group 37 - Steering...4629
Table of Contents...4630
Specifications...4631
Structure and Operation...4633
1. Steering System...4633
2. Fluid Flow...4633
3. Power Steering Booster...4634
4. Power Steering Oil Pump...4636
Troubleshooting...4639
On-Vehicle Inspection and Adjustment...4643
1. Change of Power Steering Fluid...4643
2. Bleeding of Power Steering System...4644
3. Performance Verification Test of Power Steering System...4645
4. Steering Wheel Play...4646
5. Steering Column Looseness...4646
6. Inspection of Drag Link Ball Joint...4646
Steering Column...4647
Power Steering Booster and Drag Link...4653
Power Steering Oil Pump...4677
FK...4677
FM...4681
Power Steering Oil Tank...4687
Group 41 - Bumper and Frame...4688
Table of Contents...4689
Specifications...4690
Structure and Operation...4691
1. Frame...4691
Front Bumper...4692
Frame...4694
Group 42 - Cab...4699
Table of Contents...4700
Specifications...4701
Structure and Operation...4703
1. Front Cab Mounting...4703
2. Rear Cab Mounting...4705
3. Cab Tilt Link...4706
Troubleshooting...4707
Removal and Installation of Cab...4711
Front Cab Mounting...4717
Rear Cab Mounting...4721
Cab Tilt Link...4723
Cab Stay...4725
Group 43 - Door...4726
Table of Contents...4727
Specifications...4728
Structure and Operation...4730
1. Door Locking System...4730
2. Door Glass Opening System...4731
Troubleshooting...4732
On-Vehicle Inspection and Adjustment...4734
1. Adjustment of Door Alignment...4734
Door...4736
Group 51 - Exterior...4746
Table of Contents...4747
Structure and Operation...4748
1. Wiper and Washer System...4748
Troubleshooting...4749
Mirror...4750
Wiper and Washer...4752
Front Panel...4758
Front Grille...4762
Corner Panel...4764
Fender...4766
Step...4768
No. 1 Step...4768
No. 2 Step...4770
Wheel House...4772
Window Glass...4776
Group 52 - Interior...4780
Table of Contents...4781
Specifications...4782
Structure and Operation...4784
1. Air Suspension Seat...4784
2. Emergency Locking Retractor Type Seat Belt...4786
Troubleshooting...4787
Driver Seat...4788
Side Seat...4792
Seat Belt...4793
Instrument Panel...4794
Floor Console...4805
Scuff Plate, Trim...4806
Head Lining...4810
Group 54 - Electrical...4813
Table of Contents...4814
How To Read This Group...4817
54-00A - General...4821
Precautions for Maintenance Operation...4822
54-00B - Specifications...4832
Specifications...4833
54-00C - Structure and Operation...4836
1. Starter...4837
2. Alternator...4838
3. Headlamps...4841
4. Meter Cluster...4842
5. Daytime Running Light (DRL) System...4853
6. MUTIC (Multipurpose Timing Control Unit)...4855
7. Starter Continuous Energizing Preventing Function and Preheating Function...4858
54-00D - Troubleshooting...4862
Troubleshooting...4863
54-01 - Power, Charge and Ground Circuit...4871
High-Current Fuse Box...4872
Relay and Fuse Box...4874
104 - Relay and Fuse Box Circuit...4876
110 - Power Circuit...4877
115 - Reserve Power Circuit...4889
125 - Battery Charging Circuit...4890
130 - Ground...4892
54-02 - Starting and Preheating Circuit...4912
210 - Engine Starting Circuit...4913
215 - Engine Stopping Circuit...3007
220 - Engine Preheating Circuit...4919
54-03 - Lighting Circuit...4920
310 - Headlamp Circuit...4921
313 - Daytime Running Light Circuit...4923
320 - Tail, Clearance, and License Plate Lamps Circuit...4925
325 - Stop Lamp Circuit...4926
330 - Turn Signal and Hazard Lamp Circuit...4927
340 - Backup Lamp Circuit...4929
345 - Cab Lamp Circuit...4932
348 - Illumination Lamp Circuit...4933
349 - Identification and Side Marker Lamp Circuit...4934
352 - Van Body Dome Light Circuit...4935
54-04 - Meter Circuit...4936
401 - Meter Cluster Internal Circuit...4937
410 - Tachometer Circuit...4939
412 - Speedometer Circuit...4940
420 - Fuel Gauge Circuit...4943
425 - Water Temperature Gauge Circuit...4944
436 - Air Gauge Circuit...4945
54-05 - Indicator and Warning Lamp Circuit...4946
510 - Parking Brake Indicator Circuit...4947
515 - Brake Warning Circuit...4949
530 - Water Level and Overheating Warning Circuit...4951
535 - Engine Oil Level Warning Circuit...4952
536 - Engine Oil Pressure Warning Circuit...4953
538 - Engine Oil Filter Warning Circuit...4954
550 - Cab Tilt Warning Circuit...4955
566 - Fuel Filter Warning Circuit...4956
54-06 - Cab Side Electrical Circuit...4957
610 - Cigarette Lighter Circuit...4958
612 - Audio Circuit...4959
614 - Wiper and Washer Circuit...4960
616 - Horn Circuit...4961
620 - Air-Conditioner Circuit...4962
622 - Power Window and Central Door Lock Unit...4964
629 - Mirror Heater Circuit...4965
54-07 - Chassis Side Electrical Circuit...4966
710 - Exhaust Brake Circuit...4967
718 - Air Dryer Circuit...4970
722 - Air Suspension Circuit...4971
54-08 - Engine and Transmission Side Electrical Circuit...4973
850 - Transmission Power Take-Off Circuit...4974
54-09 - Other Circuit...4975
905 - Joint Connector (J/C)...4976
Common Rail System Electric Circuit Diagram...3007
Cruise Control System Electric Circuit Diagram...3788
Automatic Transmission System Electric Circuit Diagram...4056
(Allison 1000RDS, 2200RDS)...4056
(Allison 3000RDS)...4114
Anti-Lock Brake System Electric Circuit Diagram...4542
54-10 - Electrical Equipment Installation Positions...4983
A - Switch...4984
B - Relay and Electronic Control Unit...4986
C - Meter, Sensor, Buzzer and Motor...4990
D - Air-Conditioner...4992
E - Door and Mirror...4993
F - Roof...4994
G - Cab...4995
H - Cab Tilt...4996
J - Joints of Main Harness Connectors...4998
R - Engine...5001
S - Transmission...5002
T - Switch and Sensor...5004
U - Fuse and Connectors...5008
V - Magnetic Valve...5010
W - Buzzer...5010
X - Other...5012
54-11 - Inspection of Electrical Equipment...5015
#001 to #179 - Switch...5016
#180 to #249 - Relay...5023
#250 to #349 - Sensor...5024
#350 to #409 - Control Unit...5027
#410 to #509 - Motor...5028
#510 to #539 - Actuator...5029
#560 to #609 - Magnetic Valve...5030
#610 to #649 - Buzzer, Horn...5031
#650 to #699 - Lamp...5031
#750 to #859 - Other...5032
#860 - Battery...5035
#890 - Meter...5038
54-12 - Starter and Alternator...5039
#930 - Starter...5040
#940 - Alternator...5054
54-13 - On-Vehicle Inspection and Adjustment...5061
#950 - Inspection of Alternator...5062
#951 - Inspection of Regulator...5063
#955 - Inspection of Preheating System...5064
#960 - Headlamp Aiming...5066
#965 - Inspection of Brake Fluid Level Switch...5068
54-14 - Connector Configuration Chart...5069
Connector Configuration Chart...5070
Group 55 - Heater, Air-Conditioner and Ventilation...5152
Table of Contents...5153
Specifications...5154
Structure and Operation...5156
1. Heater...5156
2. Air-Conditioner...5157
3. Air Duct...5158
4. Air-Conditioner Control...5159
Troubleshooting...5161
On-Vehicle Inspection and Adjustment...5162
1. Recovery of Refrigerant...5162
2. Recharging the System with Refrigerant...5163
3. Checking Refrigerant Charge Level...5165
4. Adding Refrigerant...5166
5. Cleaning and Replacement of Evaporator...5167
6. Cleaning and Replacement of Heater Core...5169
Connecting Air-Conditioner Piping...5172
Compressor...5173
Condenser...5174
Air-Conditioner Control...5176
Air Duct...5178
Cooling and Heater Unit, Blower...5180
FK.FM Series 2008 Fuso Owner's Manual (MH997284)...5182
FK.FM Series Fuso Body Builder's Drawings & Supporting Data (LTE07001-A - 2007.09)...5537
BODY BUILDER’S DRAWINGS AND SUPPORTING DATA FK.FM...0
PART II DRAWINGS AND TECHNICAL DATA...5597
1. LINE-UP CHART...5602
3.CAB/CHASSIS DRAWING...5604
3.1 FK61FJ-H...5604
3.2 FK61FK-H...5605
3.3 FK61FM-H...5606
3.4 FK62FF-G...5607
3.5 FK62FJ-G...5608
3.6 FK62FL-G...5609
3.7 FK62FM-G...5610
3.8 FK62FS-G...5611
3.9 FK62FJ-H...5612
3.10 FK62FL-H...5613
3.11 FK62FM-H...5614
3.12 FK62FS-H...5615
3.13 FK65FM-G...5616
3.14 FK65FS-G...5617
3.15 FK65FM-H...5618
3.16 FK65FS-H...5619
3.17 FM65FJ-G...5620
3.18 FM65FL-G...5621
3.19 FM65FM-G...5622
3.20 FM65FP-G...5623
3.21 FM65FJ-H...5624
3.22 FM65FL-H...5625
3.23 FM65FM-H...5626
3.24 FM65FP-H...5627
4.CAB/CHASSIS FRONT AND REAR VIEW...5628
4.1 FK61F Series...5628
4.2 FK62F Series...5629
4.3 FK65F Series...5630
4.4 FM65F Series...5631
5. DETAILS OF CROSSMEMBERS...5632
5.1 FK61F, FK62F & FK65F Series...5632
5.2 FM65F Series...5634
6. FRAME SECTION MODULUS DIAGRAM...5636
6.1 FK61F Series...5636
6.2 FK62F Series...5639
6.3 FK65F Series...5644
6.4 FM65F Series...5646
7. FORMULAS OF FRAME HEIGHT...5650
8. UPPER REBOUND LIMIT OF REAR AXLE...5651
9. FRONT AXLE...5652
10. REAR AXLE...5653
11. TIRE AND DISC WHEEL...5654
12. FRONT AND REAR SPRINGS...5655
13. PROPELLER SHAFT...5656
13.1 FK61F Series...5656
13.2 FK62F & FK65F Series...5657
13.3 FM65F Series...5658
14. EXHAUST SYSTEM...5659
14.1 FK6□FJ, FK, FL, FM, FS Series...5659
14.2 FK62FF Series...5660
14.3 FM65F Series...5661
15. FUEL TANK...5662
16. BATTERY BOX...5663
17. AIR SERVO ASSISTANCE & AIR TANK...5664
17.1 FK61F Series...5664
17.2 FK62F, FK65F Series...5665
17.3 FM65F Series...5666
18. LICENCE PLATE LAMP...5667
19. REAR COMBINATION LAMP...5668
20. BRAKE PIPING DIAGRAM...5669
20.1 FK61F Series...5669
20.2 FK62F, FK65F Series...5670
20.3 FM65F Series...5671
21. ELECTRIC CIRCUIT DIAGRAM...5672
21.1 POWER, CHARGE AND GROUND CIRCUIT...5672
104 RELAY AND FUSE BOX CIRCUIT...5672
110 POWER CIRCUIT...5673
115 RESERVE POWER CIRCUIT...5685
125 BATTERY CHARGING CIRCUIT...5686
130 GROUND...5687
21.2 STARTING AND PREHEATING CIRCUIT...5705
210 ENGINE STARTING CIRCUIT...5705
220 ENGINE PREHEATING CIRCUIT...5710
21.3 LIGHTING CIRCUIT...5711
310 HEADLAMP CIRCUIT...5711
313 DAYTIME RUNNING LIGHT CIRCUIT...5712
320 TAIL, CLEARANCE AND LICENSE PLATE LAMP CIRCUIT...5714
325 STOP LAMP CIRCUIT...5715
330 TURN SIGNAL AND HAZARD LAMP CIRCUIT...5716
340 BACKUP LAMP CIRCUIT...5718
345 CAB LAMP CIRCUIT...5721
348 ILLUMINATION LAMP CIRCUIT...5722
349 MARKER AND IDENTIFICATION LAMP CIRCUIT...5723
352 VAN BODY DOME LIGHT CIRCUIT...5724
21.4 METER CIRCUIT...5725
401 METER CLUSTER INTERNAL CIRCUIT...5725
410 TACHOMETER CIRCUIT...5727
412 SPEEDOMETER CIRCUIT...5728
420 FUEL GAUGE CIRCUIT...5731
425 WATER TEMPERATURE GAUGE CIRCUIT...5732
436 AIR GAUGE CIRCUIT...5733
21.5 INDICATOR AND WARNING LAMP CIRCUIT...5734
510 PARKING BRAKE INDICATOR CIRCUIT...5734
515 BRAKE WARNING CIRCUIT...5736
530 WATER LEVEL WARNING CIRCUIT...5738
535 ENGINE OIL LEVEL WARNING CIRCUIT...5739
536 ENGINE OIL PRESSURE WARNING CIRCUIT...5740
538 ENGINE OIL FILTER WARNING CIRCUIT...5741
550 CAB TILT WARNING CIRCUIT...5742
566 FUEL FILTER WARNING CIRCUIT...5743
21.6 CAB SIDE ELECTRICAL CIRCUIT...5744
610 CIGARETTE LIGHTER CIRCUIT...5744
612 AUDIO CIRCUIT...5745
614 WIPER AND WASHER CIRCUIT...5746
616 HORN CIRCUIT...5747
620 AIR CONDITIONER CIRCUIT...5748
622 POWER WINDOW AND AUTO DOOR LOCK CIRCUIT...5750
629 MIRROR HEATER CIRCUIT...5751
21.7 CHASSIS SIDE ELECTRICAL CIRCUIT...5752
710 EXHAUST BRAKE CIRCUIT...5752
718 AIR DRYER CIRCUIT...5755
722 AIR SUSPENSION CIRCUIT...5756
21.8 ENGINE AND TRANSMISSION SIDE ELECTRICAL CIRCUIT...5758
850 TRANSMISSION POWER TAKE-OFF CIRCUIT...5758
21.9 OTHERS CIRCUIT...5759
905 JOINT CONNECTOR (J/C)...5759
COMMONRAIL SYSTEM ELECTRIC CIRCUIT...5766
CRUISE CONTROL SYSTEM ELECTRIC CIRCUIT...5775
AUTOMATIC TRANSMISSION CIRCUIT Allison 1000 RDS, 2200 RDS...5779
AUTOMATIC TRANSMISSION CIRCUIT Allison 3000 RDS...5783
ANTI-LOCK BRAKE SYSTEM CIRCUIT...5787
Mitsubishi Fuso FE.FG.FK.FM Series Repair Service Manual 2008-2010
